Aerosol-generating material

ABSTRACT

A process for preparing an aerosol generating material including forming a first composition having a first binder and an aerosol former, forming a second composition having a tobacco material, a filler and optionally a second binder, combining the first composition and the second composition to form a mixture of the first composition and the second composition, the mixture including the first binder, the second binder and the filler in a total amount of between about 5% and about 15% by weight of the mixture and processing the mixture of the first composition and the second composition to form the aerosol generating material.

PRIORITY CLAIM

The present application is a National Phase entry of PCT Application No. PCT/GB2021/052808, filed Oct. 29, 2021, which claims priority from GB Application No. 2017532.9, filed Nov. 5, 2020, and GB Application No. 2114586.7, filed Oct. 12, 2021, all of which are hereby fully incorporated by reference.

TECHNICAL FIELD

The present disclosure relates to an aerosol-generating material, a method for manufacturing an aerosol-generating material and articles comprising aerosol-generating material.

BACKGROUND

Certain tobacco industry products produce an aerosol during use, which is inhaled by a user. For example, tobacco heating devices heat an aerosol-generating material such as tobacco to form an aerosol by heating, but not burning, the substrate. Such tobacco industry products commonly include mouthpieces through which the aerosol passes to reach the user's mouth.

SUMMARY

According to a first aspect of the invention, there is provided a process for preparing an aerosol generating material comprising: forming a first composition comprising a first binder and an aerosol former; forming a second composition comprising a tobacco material, a filler and optionally a second binder; combining the first composition and the second composition to form a mixture of the first composition and the second composition, the mixture comprising the first binder, the second binder and the filler in a total amount of between about 5% and about 15% by weight of the mixture; and processing the mixture of the first composition and the second composition to form the aerosol generating material.

According to a second aspect of the invention, there is provided an aerosol generating material prepared by the process according to the first aspect.

According to a third aspect of the invention, there is provided an article for use in a non-combustible aerosol-provision system comprising the aerosol generating material according to the second aspect.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 depicts the steps of a process used to manufacture an aerosol-generating material;

FIG. 2 is a side-on cross-sectional view of an article comprising the aerosol-generating material;

FIG. 3 is a perspective illustration of a non-combustible aerosol provision device for generating aerosol from the aerosol-generating material of the article of FIGS. 2 ; and

FIG. 4 is a graph to show the change in nicotine and glycerol amounts in a mixture of a first composition and a second composition and the aerosol-generating material.

DETAILED DESCRIPTION

The present invention relates to a process for preparing an aerosol generating material comprising forming a first composition comprising a first binder and an aerosol former, forming a second composition comprising a tobacco material, a filler and optionally a second binder, and combining the first composition and the second composition to form a mixture of the first composition and the second composition, the mixture comprising the first binder, the optional second binder and the filler in a total amount of between about 5% and about 15% by weight of the mixture; and processing the mixture of the first composition and the second composition to form the aerosol generating material.

An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. An aerosol-generating material may be in the form of a solid, liquid or gel, which may or may not contain an active substance and/or flavorants. The aerosol-generating material may be incorporated into an article for use in the aerosol-generating system.

According to an aspect of the disclosure, there is provided an aerosol-generating material. The aerosol-generating material is arranged to generate aerosol when heated.

The water content of the aerosol-generating material described herein may vary according to, for example, the temperature, pressure and humidity conditions at which the compositions are maintained. The water content can be determined by Karl-Fisher analysis, as known to those skilled in the art.

Unless otherwise stated, as used herein, the phrases “volatile components”, “volatiles”, “total volatile”, “volatile content” and “total volatiles” are used to refer to volatile compounds, including water. The volatile content of a material may be measured as the reduction in mass when a sample is dried in a forced draft oven at a temperature regulated to 110° C.±1° C. for three hours±0.5 minutes. After drying, the sample is cooled in a desiccator to room temperature for approximately 30 minutes, to allow the sample to cool.

FIG. 1 illustrates how the aerosol-generating material may be manufactured. A first composition comprising a binder and an aerosol former and a second composition comprising tobacco material, filler and optionally a second binder are formed and mixed. In the subsequent step the first composition and the second composition are mixed and extruded. Following this, the extruded mixture of the first composition and the second composition may be dried to form a sheet of aerosol-generating material. The sheet may then be shredded in order to make the aerosol-generating material, which may then be incorporated into a consumable for a non-combustible aerosol delivery system.

The first composition, also known as the “wet mixture”, comprises an aerosol former or humectant and a binder. The first composition may also comprise other liquids or suspensions disclosed herein. The first composition may be in a liquid phase.

The first composition comprises an aerosol former. The aerosol former comprises one or more constituents capable of forming an aerosol. The aerosol former comprises one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some embodiments, the aerosol former is glycerine, glycerol or propylene glycol.

The first composition comprises a first binder. The binder is arranged to bind the components of the first composition. Once combined with the second composition, the binder binds the components of the first and second compositions to form the aerosol-generating material. The first composition can comprise more than one binder. In such embodiments, the binders in the first composition can be the same or different.

The binder may be selected from one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the binder comprises alginate and/or pectin or carrageenan. In some embodiments, the binder comprises CMC.

The second composition, also known as the “dry mixture”, comprises a tobacco material, a filler and optionally a second binder. The second composition may also comprise other solids or gels disclosed herein. The second composition may be in the solid phase.

As used herein, the term “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material may be in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, paper reconstituted tobacco, or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/or tobacco extract.

The tobacco material may be a particulate or granular material. In some embodiments, the tobacco material is a powder or may be ground. Alternatively or in addition, the tobacco material may comprise strips, strands or fibres of tobacco. For example, the tobacco material may comprise particles, granules, fibres, strips and/or strands of tobacco. In some embodiments, the tobacco material consists of particles or granules of tobacco material. In some embodiments, the tobacco material is in a particulate or ground form, as this assists with the formation of a dough-like material that is formed when the first and second compositions are combined.

In embodiments in which the tobacco is a particulate tobacco material, each particle of the particulate tobacco material may have a maximum dimension. As used herein, the term “maximum dimension” refers to the longest straight line distance from any point on the surface of a particle of tobacco, or on a particle surface, to any other surface point on the same particle of tobacco, or particle surface. The maximum dimension of a particle of particulate tobacco material may be measured using scanning electron microscopy (SEM).

In some embodiments, the maximum dimension of each particle of tobacco material is up to about 800 μm. In some embodiments, the maximum dimension of each particle of tobacco material is up to about 2000 μm. In some embodiments, the maximum dimension of each particle of tobacco material is about 200 μm to about 800 μm.

A population of particles of the tobacco material may have a particle size distribution (D90) of at least about 100 μm. In some embodiments, a population of particles of the tobacco material has a particle size distribution (D90) of at least about 50 μm, of at least about 60, of at least about 70 μm, of at least about 80 μm, of at least about 90 , of at least about 100 μm, of at least about no μm, of at least about 120 μm, of at least about 130 μm. In some embodiments, a population of particles of the tobacco material has a particle size distribution (D90) of at most about 720 μm, of at most about 740 μm, of at most about 760 μm, of at most about 780 μm, of at most about 800 μm, of at most about 820 μm, of at most about 840 μm, of at most about 860 μm. In some embodiments, a population of particles of the tobacco material has a particle size distribution (D90) of about 600 μm. A particle size and shape analyser, such as a Camsizer may be used to measure the particle size distribution, and sieve analysis may be used to determine the particle size distribution of the particles of tobacco material.

The inventors have found that the particle size distribution (D90) of the tobacco material may be controlled to achieve the desired area density of the aerosol-generating material, and the sheet, shredded sheet or product produced therefrom. The area density of the material may be measured in GSM (grams per square metre or g/m²). For example, lower particle size distributions (D90) are associated with higher area densities. When the aerosol-generating material is incorporated into an article for use in a non-combustible aerosol provision system, this higher area density may decrease the fill-value of the tobacco material. A particular example of this is that a particle size distribution (D90) of 300 is predicted to provide an area density of 246.6 g/m².

The inventors have also noted that a lower area density is also associated with better taste and sensory properties of the aerosol-generating material, and the sheet, shredded sheet or product produced therefrom. As the process for producing the aerosol-generating material produced by the process of the present disclosure involves less drying than conventional processes, fewer volatile components, many of which are considered to be desirable are lost. The taste and aroma is better retained and so this is associated with better sensory properties. In addition, the process requires less energy to remove volatile compounds.

However, the area density cannot be too low, as this is associated with poor sensory properties due to the decreased quantity of tobacco in the material, which consumers find to provide positive sensory properties. In addition, a material having a high area density may comprise more tobacco material, and so reducing the area density may reduce the amount of tobacco material that is needed, which can confer further economic advantages.

The inventors have found that the particle size distribution (D90) may be controlled to achieve the desired tensile strength of the aerosol-generating material, and the sheet, shredded sheet or product produced therefrom. For example, higher particle size distributions (D90) are associated with lower tensile strengths. Without wishing to be bound by reason, when the particle size distribution is higher, there is less material to be bound together. This may make the aerosol-generating material, and the sheet, shredded sheet or product produced therefrom weaker and so the tensile strength is lower. A particular example of this is that a particle size distribution (D90) of 269.2 is predicted to provide a tensile strength of 7.4 N/15 mm.

The inventors have found that there is a balance between the optimum area density and the tensile strength of the aerosol-generating material, and the sheet, shredded sheet or product produced therefrom, and that this balance can be achieved by selection of the particle size distribution (D90). The particle size distribution (D90) should be low enough to provide an adequate tensile strength, but be high enough to provide an area density that provides positive sensory properties for the user and provides easier removal of volatile compounds.

w For example, the particle size distribution (D90) may be selected to provide a low enough area density to provide positive sensory properties, but a high enough tensile strength to be within the operational limits of the manufacturing machinery. A particle size distribution (D90) of at least about 100 μm is thought to contribute to the tensile strength of the aerosol-generating material. The inventors have found that a is particle size distribution (D90) of less than 100 μm provides an aerosol-generating material which a good tensile strength. However, the inclusion of such fine particles of tobacco material in the aerosol-generating material can increase its density. When the aerosol-generating material is incorporated into an article for use in a non-combustible aerosol provision system, this higher density may decrease the fill-value of the tobacco material. Advantageously, the inventors have found that a balance between a satisfactory tensile strength and suitable area density (and thus fill-value) may be achieved where the particle size distribution (D90) is at least 100 μm. In some embodiments, the particle size distribution (D90) is 100-800 μm.

In some embodiments, the particle size distribution (D90) is 160-450 μm. In some embodiments, the particle size distribution (D90) is 200-450 μm.

A particle size distribution (D90) of at least about 180 μm is thought to contribute to a suitable tensile strength of the aerosol-generating material. The inventors have found that a particle size distribution (D90) of at least about 200 μm provides an aerosol-generating material with a good tensile strength. The inclusion of finer particles of tobacco material in the aerosol-generating material can increase its area density.

Selection of the particle size distribution (D90) can provide an adequate tensile strength and area density of the aerosol-generating material that are the same or an improvement on aerosol-generating materials that are produced via “bandcasting” techniques. As noted in Example 3, compared to an aerosol-generating material produced via a bandcasting method, the aerosol-generating material produced via the inventive method had a higher area density and density, whilst maintaining an adequate tensile strength.

The second composition comprises a filler. The filler is generally a non-tobacco component, that is, a component that does not include ingredients or components originating from tobacco. The filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may be a non-tobacco fibre such as wood fibre or pulp or wheat fibre. The filler can be a material comprising cellulose or a material comprises a derivate of cellulose. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material. In some embodiments, the filler is cellulosic material, cellulose or CMC. In some embodiments, the filler is essentially composed or consists of cellulose.

In particular embodiments which include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood, wood pulp, hemp fibre, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that including fibrous filler may increase the tensile strength of the aerosol-generating material that is formed. The use of cellulose as a filler has been found to have a particularly favourable impact on the burst strength of the aerosol-generating material.

The filler may also contribute to the texture of the aerosol-generating material. For example, a fibrous filler, such as cellulose, may provide an aerosol-generating material having relatively rough first and second surfaces. Conversely, a non-fibrous, particulate filler, such as powdered chalk, may provide an aerosol-generating material having relatively smooth first and second surfaces. In some embodiments, the aerosol-generating material comprises a combination of different filler materials. The filler may help to improve the general structural properties of the aerosol-generating material, such as its tensile strength and burst strength.

Incorporating relatively high quantities of the first binder relative to the aerosol former in the first composition can result in a highly viscous mixture and, as a consequence, difficulties with blending the first composition with the second composition. The inventors have found that this problem can be solved by reducing the amount of first binder in the first composition and adding a second binder (which can be the same or different to the first binder) to the second composition.

Therefore, the second composition may comprise an optional second binder. In some embodiments of the invention, the first and the second binders are the same. In some embodiments of the invention, the first and the second binders are the different. The binder may be selected from one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the binder comprises alginate and/or pectin or carrageenan. In some embodiments, the binder comprises CMC.

As noted previously, by incorporating the second binder into the second composition, the amount of first binder in the first composition can be reduced, thus lowering the viscosity of the first composition and facilitating the formation of a mixture of the first composition and the second composition. The binder may at least partially coat the surface of the tobacco material. Where the tobacco material is in a particulate form, the binder may at least partially coat the surface of the particles of tobacco and bind them together.

30 The total volatile content of the second composition may be about 10-15% by weight of the second composition. The total volatile content may be about 5%, 10%, 15%, 20%, 25%, 30%, 35% or 40% by weight of the second composition.

The first and the second compositions described herein may be mixed to provide a mixture of the first composition and the second composition. The mixture of the first composition and the second composition may be formed by homogenising the first composition and the second composition. The mixture of the first composition and the second composition may be in the form of a “dough”. Advantageously, minimal addition water, or no water at all, is required to be added to the mixture to provide a homogenous dough that is suitable for subsequent processing steps. For example, the dough may then be extruded via a die, through which a homogenous dough may suitably pass without the further addition of water or the addition of a small amount of water.

The inventors have found that mixing the first binder, aerosol generating material, tobacco material filler and optional second binder in a single step (i.e. without forming the first and second compositions separately and then combining them) can result in a viscous mixture that is difficult to process and handle. By forming the first composition and second is composition separately and then combining these compositions, the resultant “dough”-like mixture can be more easily processed.

The tobacco material may be present in an amount of from about 50 to about 80% by weight of the mixture of the first composition and the second composition. For example, the tobacco material may be present in an amount of about 50%, 60%, 70%, 80%, or 90% by weight of the mixture of the first composition and the second composition. In some embodiments, the tobacco material is present in an amount of about 75% by weight of the mixture of the first composition and the second composition.

The filler component may be present in an amount of 0 to 20% by weight of the mixture of the first composition and the second composition, or in an amount of from 1 to 10% by weight of the mixture of the first composition and the second composition. For example, the filler may be present in an amount of greater than about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9% or 10% by weight of the mixture of the first composition and the second composition. In some embodiments, the filler component is present in an amount of 5% by weight of the mixture of the first composition and the second composition, as the inventors have found that the inclusion of 5% of the filler improves the burst strength and reduces the brittle nature of the aerosol-generating material.

The aerosol former may be present in an amount of from about 10% to about 25% by weight of the mixture of the first composition and the second composition, or in an amount of from 1 to about 10% by weight of the mixture of the first composition and the second composition. For example, the aerosol former may be present in an amount of about 10%, 12%, 15%, 18%, 20%, or 25% by weight of the mixture of the first composition and the second composition. In some embodiments, the aerosol former is present in an amount of about 15% by weight of the mixture of the first composition and the second composition.

The binder may be present in an amount of from about 1 to about 20% by weight of the mixture of the first composition and the second composition, or in an amount of from 1 to about 10% by weight of the mixture of the first composition and the second composition. For example, the binder may be present in an amount of greater than about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9% or 10% by weight of the mixture of the first composition and the second composition. In some embodiments, the binder is present in an amount of greater than about 2% by weight of the mixture of the first composition and the second composition. In some embodiments, the binder is present in an amount of about, or up to about, 5% by weight of the mixture of the first composition and the second composition. The amount of binder in the first composition, second composition and mixture of the first and second compositions is important as this alters the consistency of the compositions and mixtures. Too much binder may cause the composition/mixture to be too viscous to be processed, for example by pumps and machinery.

In embodiments of the invention in which there is provided a first and a second binder, the ratio of the first binder to the second binder may be between 1:1 and 1:10. This is advantageously selected to maintain the physical properties of the sheet and to provide adequate binding of the mixture and/or the aerosol-generating material without altering the texture of the composition negatively. The ratio between the first and the second binder may be about 1:10, 2:8, 3:7, 4:6, 5:5, 10:1, 8:2, 7:3, 6:4 respectively. In some embodiments, the ratio between the first binder to the second binder is 4:6 respectively to maintain the physical properties sheet or shredded sheet. Including all the binder in the first composition may make the first composition become too viscous to be processed, for example by pumps and machinery. Providing the binder in both the first composition and the second composition makes the compositions easier to process.

The inventors have unexpectedly found that the incorporation of the first binder, the optional second binder and the filler in a total amount of between about 5% and about 15% by weight of the mixture of the first composition and the second composition has a beneficial effect on the burst strength, strength and flexibility of the aerosol-generating material. The mixture of the first composition and the second composition may comprise about 2%, about 5%, about 8%, about 10%, about 12% or about 15% on a dry weight basis in total of the first binder, the optional second binder and the filler. In some embodiments, the mixture of the first composition and the second composition comprises 5% the first binder and the optional second binder and 5% the filler. This incorporation of the first binder, the optional second binder and the filler may decrease the tackiness, increase its burst strength and improve flexibility of the aerosol-generating material.

In a particular embodiment, the first and optional second binder are both CMC, the total amount of binder is 5%, the filler is cellulose and the total amount of cellulose is 5%. Thus, in such an embodiment, the mixture of the first composition and the second composition comprises 5% CMC and 5% cellulose. The inventors have found the presence of the binder and the filler in these amounts to have a particularly beneficial effect on the physical properties of the aerosol-generating material, including improved strength and flexibility. Cellulose filler improves the burst strength and reduces the brittleness of the aerosol-generating material.

The aerosol-generating material may have a burst strength of at least about 75 g, at least about 100 g or at least about 200 g. In some embodiments the aerosol-generating material may have a burst strength of at least 150 g.

If the burst strength is too low the aerosol-generating material may be relatively brittle. As discussed herein, the aerosol-generating material may be formed into a sheet or a shredded sheet. As a consequence, breakages in the sheet or shredded sheet may occur during the process of manufacturing the aerosol-generating material. For example, when the sheet is shredded to form a shredded sheet by a cutting process, the sheet may shatter or break into pieces or shards when cut. The incorporation of the first binder, the optional second binder and the filler may help to improve the general structural properties of the aerosol-generating material, such as its tensile strength and burst strength.

The volatile content of the mixture of the first and second compositions may be greater than 20% by weight of the mixture of the first composition and the second composition. The volatile content may be greater than about 5%, 10%, 15%, 20%, 25%, 30%, 40% by weight of the mixture of the first composition and the second composition. In some embodiments, about 20 to about 30% water is added to the mixture of the first composition and the second composition. In some embodiments, about 26% water is added.

The total volatile content of the mixture of the first composition and the second composition may be about 22-29% by weight. The total volatile content may be about 5%, 10%, 15%, 20%, 25%, 30%, 40% by weight of the mixture of the first composition and the second composition.

The water content of the mixture of the first and second compositions may be greater than 20% by weight of the mixture of the first composition and the second composition. The water content may be greater than about 5%, 10%, 15%, 20%, 25%, 30%, 40% by weight of the mixture of the first composition and the second composition. In some embodiments, about 20 to about 30% water is added to the mixture of the first composition and the second composition. In some embodiments, about 26% water is added.

The total water content of the mixture of the first composition and the second composition may be about 22-29% by weight. The total water content may be about 5%, 10%, 15%, 20%, 25%, 30%, 40% by weight of the mixture of the first composition and the second composition.

The invention enjoys the additional advantage that less water is required to make the dough-like mixture of the first composition and the second composition that in other traditional compositions. This has the advantage that the mixture of the first composition and the second composition can therefore be easily mixed without the need to add additional water or agents to form a homogenous mix that is suitable for extrusion. An additional benefit of the lower amount of water necessary is that this improves the reliability of the manufacturing process. As a consequence, the manufacturing process is also repeatable, which also has cost-saving implications. The total water content of the mixture of the first composition and the second composition is therefore relatively low.

As a consequence of this lower water content, less water is required to be removed during the processing stages. For example, a “bandcasting” process uses a slurry of which the target water content is about 75% to about 80%. This slurry must then be dried to a target water content of about 13%, therefore requiring a loss of about 67% of water. In the invention disclosed herein, minimal water is incorporated into the mixture of the first composition and the second composition. For example, from the resultant dough to the final product, there may be a loss of only about 16% of water. Therefore, water loss may be about 50% or about 60% lower in the process described herein compared to methods to form aerosol-generating materials that comprise a slurry such as a bandcasting process.

Advantageously, as less water is required to be removed during the processing stages, less energy is consumed. This is both more environmentally friendly, faster and cost efficient. In addition, as less drying is required, the taste and aroma is more retained.

The aerosol-generating material that is produced by the process disclosed herein has a volatile content of between about 5% and about 15%. This enables the aerosol-generating material to be cut into strips with relative ease. If the volatile content, in particular the water content, is too high, the aerosol-generating material may tear during the cutting process, which is undesirable. If the volatile content is too low, it may be too brittle and shatter during the cutting process.

The invention enjoys the further advantage that a smaller amount of certain volatile components, in particular nicotine and glycerol, are lost during drying of the mixture of the first and second compositions. Without wishing to be bound by reason, the mixture of the first composition and the second composition comprises a relatively low water content and as such requires less drying than a slurry that is known to the skilled person. For example, cooler temperatures and shorter drying times may be employed to achieve the desired volatile content of the aerosol-generating material. This also reduces the loss of certain valuable volatile components, resulting in improved flavour, taste and mouth-feel properties of the aerosol generated in the final product.

In an exemplary embodiment, the mixture of the first composition and the second composition comprises about 75% tobacco material (tobacco), about 15% aerosol former (glycerine), about 5% filler (cellulose), about 5% binder (CMC, about 2% in first composition, and about 3% in second composition). In this embodiment, the composition does not comprise guar gum. The inventors have found that this mixture of the first composition and the second composition provides the advantages disclosed herein.

The mixture of the first composition and the second composition, once formed and mixed, may be extruded using any extrusion technique or apparatus known in the art to from the aerosol-generating material.

Extrusion involves the feeding of a precursor composition through an orifice to produce an extruded agglomerate. The process, which applies pressure to the precursor composition combined with shear forces, results in agglomerated structures, which may be in the form of a sheet.

Extrusion may be performed using one of the main classes of extruders: screw, sieve and basket, roll, ram and pin barrel extruders. Forming the sheet structures by extrusion has the advantage that this processing combines mixing, conditioning, homogenizing and moulding of the mixture of the first composition and the second composition. Other materials may also be added during the extrusion process, such as a base, diluent, solid aerosol forming agents, solid flavour modifiers, expansion agents and other additives known in the art. This has the advantage that the additive is evenly distributed throughout the agglomerated structures formed.

The resultant extruded mixture of the first composition and the second composition may be dried using any suitable drying technique known in the art. For example, microwave, infrared, air and oven drying are suitable techniques to dry the aerosol-generating material. The temperature of the drying step may be below 100° C., and is below 90° C. in some embodiments of the invention. The drying temperature employed may be at most about 25° C., about 30° C., about 40° C., about 50° C., about 60° C., about 70° C., about 80° C., about 90° C., or about 100° C.

The resultant extruded mixture of the first composition and the second composition may be processed by forming a layer of the mixture on a surface and then the mixture may be dried to remove at least some of the water and form a sheet of the aerosol-generating material.

The water may be removed by allowing the water to evaporate from the extruded mixture at ambient temperature and pressure (for example, 25° C. and 101 kPa.) Alternatively, the water may be removed by applying heat to the extruded mixture (for example, by heating it to above about 25° C.) and/or reducing the atmospheric pressure surrounding the extruded mixture of the first composition and the second composition (for example, to less than 101 kPa).

A low drying temperature employed is advantageous as this reduces loss of volatile components, such as nicotine, glycerol and flavours, that contribute to the flavour, taste and mouth-feel of the final product. In some embodiments of the invention, there is a loss of less than about 10%, about 8%, about 5%, about 4%, about 2% or about 1% in total of nicotine and glycerol. In some embodiments, there is less than 5% loss of total volatiles. In some embodiments of the invention, there is a loss of less than about 10%, about 8%, about 5%, about 4%, about 2% or about 1% in total of glycerol and nicotine. In some embodiments, there is less than 5% loss in total of glycerol and nicotine. The aerosol-generating material therefore has a lower total volatile content than the mixture of the first composition and the second composition.

The aerosol-generating material may comprise total volatiles in an amount of less than about 20%, less than about 15%, less than about 10% or less than about 5% by weight of the aerosol-generating material. In some embodiments, the aerosol-generating material comprises total volatiles in an amount of between about 0% and about 15% or between about 5% and about 15% by weight of the aerosol-generating material. In some embodiments, the aerosol-generating material may have a total volatile content of about 9-13% by weight.

The aerosol-generating material may comprise water. The aerosol-generating material may comprise water in an amount of less than about 20%, less than about 15%, less than about 10% or less than about 5% by weight of the aerosol-generating material. In some embodiments, the aerosol-generating material comprises water in an amount of between about 0% and about 15% or between about 5% and about 15% by weight of the aerosol-generating material. In some embodiments, the aerosol-generating material comprises water in an amount of between about 5% and about 15% by weight of the aerosol-generating material. The aerosol-generating material therefore has a lower water content than the mixture of the first composition and the second composition.

In some embodiments, the loss of water from the mixture of the first and second composition and the aerosol-generating material is between 10-50%. In some embodiments of the invention, there is a loss of about 10%, about 15%, about 25%, about 30%, about 40% or about 50% of water. In some embodiments, there is a loss of about 26% of water.

A sheet or shredded sheet of the aerosol-generating material may comprise water and an aerosol former, in a total amount, of less than about 30% by weight of the sheet or shredded sheet of aerosol-generating material or less than about 25% by weight of the aerosol-generating material. It is thought that incorporating water and aerosol former in the sheet or shredded sheet of aerosol-generating material in an amount of less than about 30% by weight of the sheet or shredded sheet of aerosol-generating material may advantageously reduce the tackiness of the sheet. This may improve the ease by which the aerosol-generating material can be handled during processing. For example, it may be easier to roll a sheet of aerosol-generating material to form a bobbin of material and then unroll the bobbin without the layers of sheet sticking together. Reducing the tackiness may also decrease the propensity for strands or strips of shredded material to clump or stick together, thus further improving processing efficiency and the quality of the final product.

After drying, the sheet of aerosol-generating material may be cut into strips or strands of aerosol-generating material. A single thickness of the sheet of aerosol-generating material may be fed into a shredding apparatus. This can be achieved, for example, by providing a bobbin of sheet material which can be continuously fed into a shredding apparatus. Alternatively, a discrete portion of the aerosol-generating material in sheet form, such as a sheet known to those skilled in the art as a flag, can be fed into a shredding apparatus. The strips or strands of aerosol-generating material can be gathered and formed into an article for use in a non-combustible aerosol provision system. Optionally, the aerosol-generating material can be crimped prior to being gathered and formed into the article. Optionally the aerosol-generating material may be subject to a second cutting step, such as in a cross-cut type shredding process, to obtain a defined cut length.

The first and/or second surfaces of the sheet or shredded sheet may be relatively uniform (e.g. they may be relatively smooth) or they may be uneven or irregular. For example, the first and/or second surfaces of the sheet may be textured or patterned to define a relatively coarse surface. In some embodiments, the first and/or second surfaces are relatively rough.

The smoothness of the first and second surfaces may be influenced by a number of factors, such as the area density of the sheet or shredded sheet, the nature of the components that make up the aerosol-generating material or whether the surfaces of the material have been manipulated, for example embossed, scored or otherwise altered to confer them with a pattern or texture.

The sheet or shredded sheet of aerosol-generating material has a thickness of at least about 100 μm. The sheet or the shredded sheet may have a thickness of at least about 100 μm, 120 μm, 140 μm, 160 μm, 180 μm, 200 μm, 220 μm, 240 μm, 260 μm, 280 μm, 290 μm, or 300 In some embodiments, the sheet or shredded sheet has a thickness of from about 100 μm to about 300 μm, from about 151 μm to about 299 μm, from about 152 μm to about 298 μm, from about 153 μm to about 297 μm, from about 154 μm to about 296 μm, from about 155 μm to about 295 μm, from about 156 μm to about 294 μm, from about 157 μm to about 293 μm, from about 158 μm to about 292 μm, from about 159 μm to about 291 μm or from about 160 μm to about 290 μm. In some embodiments, the sheet or shredded sheet has a thickness of from about 170 μm to about 280 μm, from about 180 to about 270 μm, from about 190 to about 260 μm, from about 200 μm to about 250 μm or from about 210 μm to about 240 μm. In some embodiments, the thickness of the sheet or shredded sheet is about 200 μm.

The thickness of the sheet or shredded sheet may vary between the first and second surfaces. In some embodiments, an individual strip or piece of the aerosol-generating material has a minimum thickness over its area of about 100 μm. In some cases, an individual strip or piece of the sheet or shredded sheet of aerosol-generating material has a minimum thickness over its area of about 0.05 mm or about 0.1 mm. In some cases, an individual strip, strand or piece of the sheet or shredded sheet of aerosol-generating material has a maximum thickness over its area of about 1.0 mm. In some cases, an individual strip or piece of the aerosol-generating material has a maximum thickness over its area of about 0.5 mm or about 0.3 mm.

The thickness of the sheet can be determined using ISO 534:2011 “Paper and Board-Determination of Thickness”.

The inventors have established that, if the sheet or shredded sheet of aerosol-generating material is too thick, then heating efficiency can be compromised. This can adversely affect power consumption in use, for instance the power consumption for release of flavour from the aerosol-generating material. Conversely, if the sheet or shredded sheet of aerosol-generating material is too thin, it can be difficult to manufacture and handle; a very thin material can be harder to cast and may be fragile, compromising aerosol formation in use.

It is postulated that if the sheet or shredded sheet of aerosol-generating material is too thin (e.g. less than 100 μm), then it may be necessary to increase the cut width of the shredded sheet to achieve sufficient packing of the sheet or shredded sheet of aerosol-generating material when it is incorporated into the article. Increasing the cut width of the shredded sheet can increase the pressure drop, which is undesirable.

It is postulated that an aerosol-generating material having a thickness of at least about 100 μm, along with an area density of from about 100 g/m² to about 240 or 250 g/m² is less liable to tear, split or become otherwise deformed during its manufacture. In addition an aerosol-generating material with an area density of from about 100 g/m² to about 240 or 250 g/m² is less liable to tear, split or become otherwise deformed during its manufacture. A thickness of at least about 100 μm may have a positive effect on the overall structural integrity and strength of sheet or shredded sheet. For example, it may have a good tensile strength and thus be relatively easy to process. In some embodiments, the area density is between about 170 and about 240 or 250 g/m². In some embodiments, the area density is about 180 g/m².

The thickness of the sheet or shredded sheet is also thought to have a bearing on its area density. That is to say, increasing the thickness of the sheet or shredded sheet may increase the area density of the sheet or shredded sheet.

Conversely, decreasing the thickness of the sheet or shredded sheet may decrease the area density of the sheet or shredded sheet. For the avoidance of doubt, where reference is made herein to area density, this refers to an average area density calculated for a given strip, strand, piece or sheet of the aerosol-generating material, the area density calculated by measuring the surface area and weight of the given strip, strand, piece or sheet of is aerosol-generating material.

The sheet or shredded sheet of aerosol-generating material has an area density of from about 100 g/m² to about 250 g/m². The sheet or shredded sheet may have an area density of from about 110 g/m² to about 240 g/m², from about 120 g/m² to about 230 g/m², from about 130 g/m² to about 220 g/m² or from about 140 g/m² to about 210 g/m². In some embodiments, the sheet or shredded sheet has an area density of from about 130 g/m² to about 190 g/m², from about 140 g/m² to about 180 g/m², from about 150 g/m² to about 170 g/m². In some embodiments, the sheet or shredded sheet has an area density of about 180 g/m².

The area density of about loo g/m² to about 250 g/m² is thought to contribute to the strength and flexibility of sheet or shredded sheet. Furthermore, the inventors have found that a rod comprising a shredded sheet of aerosol-generating material having an area density of around 180 gsm and a minimum thickness of 220-230 μm can be can be packed such that the aerosol-generating material stays in place within the rod whilst maintaining a desired weight of tobacco material within the rod (e.g. around 300 mg) and delivering acceptable organoleptic properties (e.g. taste and smell) when heated in a non-combustible aerosol provision device.

The flexibility of the sheet or shredded sheet is considered to be dependent, at least in part, upon the thickness and area density of the sheet or shredded sheet. A thicker sheet or shredded sheet may be less flexible than a thinner sheet or shredded sheet. Also, the greater the area density of the sheet, the less flexible the sheet or shredded sheet is. It is thought that the combined thickness and area density of the aerosol-generating material described herein provides a sheet or shredded sheet that is relatively flexible. When the aerosol-generating material is incorporated into an article for use in a non-combustible aerosol-provision device, this flexibility, may give rise to various advantages. For example, the strands or strips are able to readily deform and flex when an aerosol generator is inserted into the aerosol-generating material, thus facilitating insertion of an aerosol generator (e.g. a heater) into the material and also improving retention of the aerosol generator by the aerosol-generating material.

The inventors have found that the area density of the sheet or shredded sheet of aerosol-generating material influences the roughness of the first and second surfaces of the sheet or shredded sheet. By changing the area density, the roughness of the first and/or second surfaces can be tailored.

The sheet or shredded sheet may have a tensile strength of at least 4 N/15 mm.

The inventors have found that, where the sheet or shredded sheet has a tensile strength below 4 N/15 mm, the sheet or shredded sheet is likely to tear, break or otherwise deform during its manufacture and/or subsequent incorporation into an article for use in a non-combustible aerosol provision system. Tensile strength may be measured using ISO 1924:2008.

The sheet or shredded sheet of aerosol-generating material may have a burst strength of at least about 75 g, at least about 100 g or at least about 200 g. In some embodiments, the burst strength of the sheet or shredded sheet of aerosol-generating material is at least 150 g. As disclosed and discussed above, the burst strength affects the strength of the material.

The sheet or shredded sheet of aerosol-generating material may have a total volatile content of about 9-13% by weight. The total volatile content may be about 5%, 10%, 15%, 20%, 25%, 30%, 40% by weight. As disclosed herein, the invention advantageously retains the amount of volatile compounds. This improves the flavour, taste and mouth-feel properties of the aerosol generated in the final product. The aerosol generating material may comprise a substance to be delivered to a user. In some embodiments, the substance to be delivered comprises an active substance.

The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term “botanical” includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.

In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

In some embodiments, additives may be incorporated into the first composition, the second composition, the mixture of the first composition and the second composition or the aerosol-generating material before or after extrusion, drying or shredding processing steps. In some embodiments, the additive comprises a substance to be delivered.

In some embodiments, the substance to be delivered comprises a flavour. The flavour may be added to any stage of the production of the aerosol generating material.

In some embodiments, the flavour is added to the first composition. This embodiment enjoys the advantage of the liquid flavour being added to the liquid composition prior to mixing the first and the second composition, and that the flavour will be distributed evenly throughout at least the first composition. This embodiment has the disadvantage that the flavour may be lost during the drying operation.

In some embodiments, the flavour may be added after the shredding operation. For example, a flavour nozzle may be provided on the machinery to deposit the flavour onto the surface of the strips of the aerosol generating material.

As used herein, the terms “flavour” and “flavorant” refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.

In some embodiments, the substance to be delivered may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

In some embodiments, the first composition, the second composition or the mixture of the first composition and the second composition may contain one or more functional materials. The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

In some embodiments, the substance to be delivered may be an aerosol-generating material, such as those described herein, or a material that is not intended to be aerosolised. As appropriate, either material may comprise one or more active constituents, one or more flavours, one or more aerosol former, and/or one or more other functional materials.

According to an aspect of the disclosure, a consumable is provided comprising an aerosol-generating material as described herein. A consumable is an article comprising aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor. The consumable may be any shape or size that is appropriate to the smoking device. In some embodiments of the invention, the consumable is a rod shape. In one aspect the aerosol-generating material is provided in an aerosol-generating device such as a tobacco-heating product (THP) or hybrid e-cigarette product.

As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes:

combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); and non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

According to the present disclosure, a “combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar.

In some embodiments, the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.

In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables may sometimes be referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.

In some embodiments, the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolised. As appropriate, either material may comprise one or more active constituents, one or more flavours, one or more aerosol former, and/or one or more other functional materials.

As disclosed herein, a non-combustible aerosol-provision system may comprise the aerosol generating material. This is exemplified in FIGS. 2 and 3 .

FIG. 2 is a side-on cross sectional view of a consumable or article 1 for use in an aerosol delivery system. The article 1 comprises a mouthpiece segment 2, and an aerosol generating segment 3.

The aerosol generating segment 3 is in the form of a cylindrical rod and comprises a aerosol-generating material 4. The aerosol-generating material can be any of the materials discussed herein.

Although described above in rod form, the aerosol-generating segment 3 can be provided in other forms, for instance a plug, pouch, or packet of material within an article.

The mouthpiece segment 2, in the illustrated embodiment, includes a body of material 5 such as a fibrous or filamentary tow.

The rod-shaped consumable 1 further comprises a wrapper 6 circumscribing the mouthpiece segment 2 and aerosol generating segment 3, such as a paper wrapper.

FIG. 3 shows an example of a non-combustible aerosol provision device loo for generating aerosol from an aerosol-generating medium/material such as the aerosol-generating material of a consumable 110, as described herein. In broad outline, the device 100 may be used to heat a replaceable article 110 comprising the aerosol-generating medium, for instance an article 1 as illustrated in FIG. 2 or as described elsewhere herein, to generate an aerosol or other inhalable medium which is inhaled by a user of the device 100. The device 100 and replaceable article 110 together form a system.

The device 100 comprises a housing 102 (in the form of an outer cover) which surrounds and houses various components of the device 100. The device 100 has an opening 104 in one end, through which the article 110 may be inserted for heating by a heating assembly. In use, the article 110 may be fully or partially inserted into the heating assembly where it may be heated by one or more components of the heater assembly.

The device 100 of this example comprises a first end member 106 which comprises a lid 108 which is moveable relative to the first end member 106 to close the opening 104 when 110 article 110 is in place. In FIG. 3 , the lid 108 is shown in an open configuration, however the lid 108 may move into a closed configuration. For example, a user may cause the lid 108 to slide in the direction of arrow “B”.

The device 100 may also include a user-operable control element 112, such as a button or switch, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the switch 112.

The device 100 may also comprise an electrical component, such as a socket/port 114, which can receive a cable to charge a battery of the device loft For example, the socket 114 may be a charging port, such as a USB charging port.

In some embodiments, the consumable 110 may comprise an aerosol-modifying agent. An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-10 modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavorant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

In some embodiments, the device may also comprise an aerosol generator. An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

EXAMPLES Example 1

Two aerosol-generating materials were prepared. Each material was prepared by forming a first composition (“liquid phase”) comprising at least one binder (CMC and optionally Guar) and an aerosol former, forming a second composition (“dry phase”) comprising a tobacco material, a filler and a second binder (CMC) and combining the first composition and the second composition to form a dough-like mixture of the first composition and the second composition. The mixture was then extruded and dried at less than 100° C. to form sheets of aerosol-generating material. The burst strengths of the two materials were measured and compared. The burst strength was measured using a calibrated Texture Analyser (50 kg load cell, 20 mm probe height calibration, 1 g contact force) and Exponent software, made by Stable Micro Systems. The burst strength was determined using a 3 cm² sheet of aerosolizable material using a 5 mm stainless steel ball probe. The composition of each material and its burst strength is provided in Table 1.

TABLE 1 Aerosol-generating material Component 1 2 Tobacco Ground 78% 75% material Tobacco Aerosol Glycerine 15% 15% former Filler Cellulose  5%  5% Binder CMC 2% (1.7% liquid 5% (2% liquid phase, 0.3% phase, 3% dry phase) dry phase) Binder Guar 0.3% (liquid 0 phase) Average Burst 134 240 Strength (g)

As can be seen from Table 1, using 2% CMC in the first composition and 3% CMC in the second composition (to a total of 5% CMC in the mixture of the first composition and second composition) provided an aerosol-generating material (aerosol-generating material 2) with a burst strength of at least 150 g. In addition, the inventors found that this was processed with 110 significant challenges with the equipment or machinery, and the burst strength was suitable for the further use in an article for use in a non-combustible aerosol provision system.

Example 2

FIG. 4 is a graph showing loss of volatile compounds nicotine (labelled “nic delta” in dashed pattern) and glycerol (labelled “glycerol delta” in dotted pattern) in three exemplary aerosol-generating materials formed using the method for preparing aerosol-generating material 2 of Example 1. The change in amount of glycerol and nicotine was measured from the dough-like mixture to the final product by gas chromatography (GC). The change in total volatile content, including water content, was measured as the percentage loss in weight when a sample is dried in a ventilated hot air oven at a temperature regulated to 110 ° C. for exactly three hours.

There is only a 0-2% loss of nicotine and glycerol combined. Additionally, there is only about a 16% loss in water. This shows an efficient and targeted drying process, removing only unwanted water, and minimal loss of volatile compounds nicotine and glycerol. Nicotine is an example of an active substance described herein and glycerol is an example of an aerosol former as described herein.

Example 3

In this Example, the physical characteristics of an aerosol-generating material produced via the bandcasting method was compared to that of an aerosol-generating material produced via the inventive method.

TABLE 2 Bandcasting Present method Attribute example example Area density (GSM or g/m²) 182 220 Density (gm³) 0.77 0.89 Tensile Strength (N/15 mm) 10.2 4.2 Thickness (um) 237 246 Water (%) 7.1 7.7 Glycerol (%) 18.2 16.9 Nicotine (%) 1.9 2

The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future. 

1. A process for preparing an aerosol generating material comprising: forming a first composition comprising a first binder and an aerosol former; forming a second composition comprising a tobacco material, a filler and optionally a second binder; combining the first composition and the second composition to form a mixture of the first composition and the second composition, the mixture comprising the first binder, the second binder and the filler in a total amount of between about 5% and about 15% by weight of the mixture; and processing the mixture of the first composition and the second composition to form the aerosol generating material.
 2. A process as claimed in claim 1, wherein processing the mixture of the first composition and the second composition comprises extruding the mixture to form a sheet of the aerosol generating material.
 3. A process as claimed in claim 2, wherein the process comprises drying the sheet of aerosol generating material.
 4. A process as claimed in claim 1, wherein the mixture of the first composition and the second composition has a volatile content of greater than about 20 wt %.
 5. A process as claimed in claim 1, wherein the aerosol generating material has a volatile content that is less than the volatile content of the mixture of the first composition and the second composition.
 6. A process as claimed in claim 1, wherein the aerosol generating material has a volatile content of less than about 20 wt %.
 7. A process as claimed in claim 1, wherein the tobacco material comprises particulate tobacco.
 8. A process as claimed in claim 1, wherein the tobacco material has a particle size distribution (D90) of 160-450 μm.
 9. A process as claimed in claim 1, wherein the first and second binders are the same or different.
 10. A process as claimed in claim 1, wherein a ratio of the first binder to the second binder is from 1:1 to about 1:10.
 11. A process as claimed in claim 1, wherein the mixture of the first composition and the second composition comprises the binder in an amount of greater than about 2% by weight of the mixture of the first composition and the second composition.
 12. A process as claimed in claim 1, wherein the mixture of the first composition and the second composition comprises the first binder, the second binder and the filler in a total amount of between 5 and 15% by weight of the mixture of the first composition and the second composition.
 13. A process as claimed in claim 1, wherein the first composition is in a liquid phase and the second composition is in a solid phase.
 14. A process as claimed in claim 1, wherein the mixture of the first composition and the second composition comprises the filler in an amount of greater than about 2% by weight of the mixture of the first composition and the second composition.
 15. A process as claimed in claim 2, wherein the process comprises shredding the sheet to form strips of the aerosol generating material.
 16. A process as claimed in claim 3, wherein the drying is performed at a temperature of less than about 100° C.
 17. A process as claimed in claim 1, wherein the mixture of the first composition and the second composition is formed by homogenizing homogenising the first composition and the second composition.
 18. An aerosol generating material prepared by a process as claimed in claim
 1. 19. An aerosol generating material as claimed in claim 18, wherein the aerosol generating material is in the form of a sheet or shredded sheet.
 20. An aerosol generating material as claimed in claim 19, wherein the sheet or shredded sheet has a burst strength of at least 150 g.
 21. An aerosol generating material as claimed in claim 18, wherein the sheet or shredded sheet has an area density of from about 170 g/m² to about 240 g/m2.
 22. An aerosol generating material as claimed in claim 18, wherein the sheet or shredded sheet has a tensile strength of from about 4 N/15 mm to about 20 N/15 mm.
 23. An aerosol generating material as claimed in claim 18, wherein the aerosol generating material comprises an amount of glycerol and/or nicotine that is between 0 and 5 wt % less than an amount of glycerol and/or nicotine comprised in the mixture of the first composition and the second composition.
 24. An article for use in a non-combustible aerosol-provision system comprising the aerosol generating material as claimed in claim
 18. 25. A non-combustible aerosol-provision system comprising the article as claimed in claim
 24. 26. Use of an aerosol generating material as claimed in claim 18 in an article for use in a non-combustible aerosol-provision system. 